Moldable product and method of producing the same



Patented Nov. 11, 1930 UNITED STATES P'ATENT OFFICE SAMUEL F. WALTON OF HAMBURG, NEW YORK, ASSIGNOR TO THE EXOLON COMPANY OF BLASDELL, NEW YORK, A CORPORATION OF MASSACHUSETTS MOLDABLE PRODUCT AND METHOD OF PRODUCING THE SAME No Drawing.

My present invention contemplates a new product of general utility for molded articles such as arenow usually made fromso-called condensation products and like materials.

Materials in accordance with my invention may be produced at low cost and have certain physical advantages which are imparted to the articles made from it.

While my invention is capable of some variations as to material and method, its principles may be illustrated by a characteristic product in which I utilize an ordinary condensation product base or material of like type with a body of porous material capable of being comminuted to any desired size and which may be embodied in the phenol resins in such a way as to become thoroughly incorporated therewith to form a mass which may be heated and molded as desired.

This product may bemade in any, color desired and for such color effects I proceed as follows. Iuse for a base or body for my product a silicateand for this purpose can utilize such a common and inexpensive material as furnace slag. Such a slag when comminuted furnishes a porous material of irregular surface. It is light and has a considerable structural strength and as a silicate offers an unusual possibility for a basis of bonding with an insoluble color vehicle such as a silicate. v

In producing a color for such a material I use a soluble silicate such as water glass mixing with this a metallic oxide of the desired color The slag particles arethen kneaded into this color mixture and the" whole dried out while the mass is being constantly stirred or agitated. When dried out the mass is then brought to a temperature not exceeding 500 C. This efiects a chemical union of the 4 silicate in the presence of the metallic oxide Application filed April 23,

any suitable solvent, as furfurol, and add to this aphenol resin in finely powdered condi commercially known, but .for my purposes such resins should be of the clear type so that the color of the mass is not hidden-by the resin. v The resultant product is characterized by lightness of weight, beauty and impermeability of color, fire retardance,and unusual tensile strength and resistance to shatter and;

shock.

What .I therefore claim and desire to secure by Letters Patent is:

. 1. A moldable product, comprising amix- I ture of particles of 'finely divided slag, having a siliceous glaze, including a metallic oxide of definite color, and a phenol resin in bonding proportion thereto.

2. A material for molding, comprising a comminuted siliceous base, having an insoluble glaze, including a metallic oxide of definite color, and a phenol resin mixed therewith and in bonding relation thereto.

3. The method of utilizing slag having a siliceous glaze including a metalhc oxide of definite color, which consists in mixing the comminuted slag with a solvent, mixing therewith a finely pulverized phenol condensation product, and molding the mix under the heat and pressure to shape, removin the shaped product from the mold, and re eating at a temperature suflicient to harden the phenol condensation product to an insoluble condition. p I

4;. The method of utilizing slag having a siliceous glaze including a metallic oxide of I definite color, which consists in mixing the.

colored slag with furfurol, mixing therewith a finely pulverized phenol condensation product, and molding the mix under heat and pressure to shape, removin the shaped prodnot from the mold, and re eating at a temmoldin themix under heat and pressure to 'shape,.1n removing'the shaped product from not from the mold, and re gerature suficient to harden the phenol conensation product tom insoluble condition.

5. The method of utilizing slag having a siliceous glaze including a metallic oxide of definite color, which consists in wetting the colored slag with furfurol, mixing therewith a finely .ulverized phenol condensation product, and molding the mix under heat and pressure to shape removin serature suflicient to harden'the phenol conensation product to an insoluble condition. 6. The'meth'od of producing a moldable product, which consists in mixing siliceous slag granules and a soluble silicate in which is incor orated an-insolubilizing and coloring oxi e which reacts withthe soluble silicate in the presence of water to form an-insoluble and colored glaze on the siliceous base, in adding a phenol condensation product, in

the mold and reheating at a'temperature to harden the phenol condensation product to an insoluble condition.

". 7. As a new product, siliceous slag granulescolored with a soluble silicate, and aninsolu billzing and colorin oxide reactive with the soluble silicate in t e-,presence"of water to. form a chemical union of the silicate in the presence of the oxide whereby an infusible glaze is de osited on the 'granules and a phenol con ensationproduct in bonding proportions theretor 1 In testimony whereof I afiix m si ature. SAMUEL F. AL ON.

the shaped prodeating at a tem- 

